**4.1 Case study**

Figure 1 shows three potential decentralized locations for biogas production. As there is a spa town located in the considered region it was not possible to contemplate a fourth, central location for a fermenter as it would infringe with the touristy activity there. There is already an existing district heating network in town that should be extended. The heat needed could be either generated by a centrally placed CHP with biogas transported via pipelines or heat produced with decentralized CHPs could be used for fermenter heating and/or transported via long –distance heat pipelines to the town. In the first case, with central CHP, fermenter heating is provided by wood chip furnace.

The fermentation could work with different feedstock types to find out the most lucrative way of using intercrops, manure, grass silage and corn silage. Corn as additional feedstock was taken into consideration for economic reasons, because it is favored under current economic conditions. For the optimization it was assumed that proportional to the availability of manure biomass in an amount of 34 % intercrops, 18 % grass silage and 16 % corn silage (referring to fresh weight) per livestock unit can be supplied. As there are several

Forschungsförderungsgesellschaft mbH (FFG), report not published yet

 1 Syn-Energy "Klima- und Wasserschutz durch synergetische Biomassenutzung – Biogas aus Zwischenfrüchten, Rest- und Abfallstoffen ohne Verschärfung der Flächenkonkurrenz"; programme responsibility: Klima- und Energiefonds; programme management: Österreichische

Economic and Ecological Potential Assessment for Biogas Production Based on Intercrops 181

investment of 150,000 € for a silage storage was taken into account. As soon as a location is chosen by the PNS a storage has to be included there. Two locations mean two times

Transportation of heat and biogas could be achieved via pipeline networks. Network energy demands as well as losses caused by transporting were included. Regarding heat it was assumed that the total produced heat amount could be used for district heating. As location 1 and 3 are in one line to the spa town one biogas pipeline could be used for both locations to transport biogas to the central CHP. Therefore no additional costs arise for a biogas pipeline from location 1, if location 3, which is farther away, supplies the center with biogas. Because of different transport distances the PNS could decide which provision group and amount of substrate should be used to get the most economical optimum solution. The fermentation could run with various substrate feeds. Dependent on them fermenter sizes, costs and exposure times differed. Seven different fermenters were part of the PNS to find

> [%] Manure Inter-crops Grass silage Corn silage 1 30 0 0 70 2 30 70 0 0 3 50 50 0 0 4 50 20 10 20 5 75 0 0 25 6 75 25 0 0 7 75 15 10 0

In Table 8 the substrate parameters are described. The optimization was based on two

\* decided by project partners Manure Corn silage Intercrops Grass silage Dry Mass Content [%] 9 33 24 30 Substrate Costs\* min. [€/t DM] 5 65 50 50 Substrate Costs\* max. [€/t DM] 10 110 80 80 CH4-output [m³/ t DM] 200 340 300 300

Table 8. Substrate parameters and costs in € per ton dry matter and cubic meter methane per

Figure 2 shows the so called maximum structure for the PNS optimization, which includes all input and output materials with energy and material flows with economic parameters like investment or operating costs and prices. For the optimization three fermenter sizes (up to a capacity that serves a 250 kWel CHP) were available for biogas production. Four combined heat and power plant capacities (up to 500 kWel) were involved in the maximum structure. The fermenters could be heated by decentralized CHPs or with a wood chip

furnace on site in case the biogas is transported to a central CHP.

different cost situations (maximum and minimum) concerning substrate provision.

investment costs to store the silage that is used for biogas production.

the most lucrative way of substrate input. The feeds are shown in Table 7.

Feed

Table 7. Substrate feeds for fermentation

ton dry matter

farmers in and around the considered region eight provider groups (1-8 according to Table 6 and black bordered providers in Figure 1) were defined. The substrate costs were the same for each group.

Fig. 1. Substrate providers (A-T) and possible fermenter locations (BGA1-3)


Table 6. Transport distances for substrate provision

The providers differed in the amount of available resources as well as in the distance to each possible fermenter location, which directly correlates with transport distances and costs. Transport costs included fix costs for loading and unloading and variable costs depending on the distance (including unloaded runs). For solid substrates fixed costs of 2 €/t fresh weight were taken into account. Similarly, the conversion was made for the variable costs, which were assumed with 0.49 €/km. Fixed transport costs for manure were defined with 20 €/t dry mass with variable costs of 5 €/t dry mass per kilometer. For grass and corn silage a storage was taken into account. As it is not possible to bring the investment costs down to one number because they are highly depending on the local basic conditions a fix investment of 150,000 € for a silage storage was taken into account. As soon as a location is chosen by the PNS a storage has to be included there. Two locations mean two times investment costs to store the silage that is used for biogas production.

Transportation of heat and biogas could be achieved via pipeline networks. Network energy demands as well as losses caused by transporting were included. Regarding heat it was assumed that the total produced heat amount could be used for district heating. As location 1 and 3 are in one line to the spa town one biogas pipeline could be used for both locations to transport biogas to the central CHP. Therefore no additional costs arise for a biogas pipeline from location 1, if location 3, which is farther away, supplies the center with biogas.

Because of different transport distances the PNS could decide which provision group and amount of substrate should be used to get the most economical optimum solution. The fermentation could run with various substrate feeds. Dependent on them fermenter sizes, costs and exposure times differed. Seven different fermenters were part of the PNS to find the most lucrative way of substrate input. The feeds are shown in Table 7.


Table 7. Substrate feeds for fermentation

180 Biogas

farmers in and around the considered region eight provider groups (1-8 according to Table 6 and black bordered providers in Figure 1) were defined. The substrate costs were the same

Fig. 1. Substrate providers (A-T) and possible fermenter locations (BGA1-3)

**Distances in km to Provider Group**

Table 6. Transport distances for substrate provision

1 (A) 1.6 3.4 0 2 (B, R) 3.3 4.7 4 3 (C, D, L) 2.7 4.6 1.2 4 (E, F, G) 1.9 1.4 3.3 5 (H, I) 0.3 2.1 2.1 6 (J, K) 1.5 2.9 3 7 (M, N) 3.1 3 2.4 8 (P, Q, S, T) 3.8 1.9 3.7

The providers differed in the amount of available resources as well as in the distance to each possible fermenter location, which directly correlates with transport distances and costs. Transport costs included fix costs for loading and unloading and variable costs depending on the distance (including unloaded runs). For solid substrates fixed costs of 2 €/t fresh weight were taken into account. Similarly, the conversion was made for the variable costs, which were assumed with 0.49 €/km. Fixed transport costs for manure were defined with 20 €/t dry mass with variable costs of 5 €/t dry mass per kilometer. For grass and corn silage a storage was taken into account. As it is not possible to bring the investment costs down to one number because they are highly depending on the local basic conditions a fix

**Location 1 Location 2 Location 3**

for each group.

In Table 8 the substrate parameters are described. The optimization was based on two different cost situations (maximum and minimum) concerning substrate provision.


Table 8. Substrate parameters and costs in € per ton dry matter and cubic meter methane per ton dry matter

Figure 2 shows the so called maximum structure for the PNS optimization, which includes all input and output materials with energy and material flows with economic parameters like investment or operating costs and prices. For the optimization three fermenter sizes (up to a capacity that serves a 250 kWel CHP) were available for biogas production. Four combined heat and power plant capacities (up to 500 kWel) were involved in the maximum structure. The fermenters could be heated by decentralized CHPs or with a wood chip furnace on site in case the biogas is transported to a central CHP.

Economic and Ecological Potential Assessment for Biogas Production Based on Intercrops 183

locations. For the pipeline coming from location 1 no additional costs have to be incurred because the pipeline would be part of the routing from location 3 to the center. The produced heat covers the central heat demand for a price of 2.25 ct/kWh. The electricity is fed into the grid and feed-in tariffs of 20.5 ct/kWh can be gained. Figure 3 depicts the

optimum structure for a situation with maximum substrate costs as listed in Table 8.

Fig. 3. Optimum structure of a technology network generated with PNS

network as well as the costs for fermenters and CHPs.

yearly amount of about 280,400 €.

With this technology network and 15 years payout period a total annual profit of around 196,350 € can be achieved (interest rates are not included). The total material costs including electricity consumed from the grid and costs for fermenter heating add up to approx. 438,000 €/yr with additionally 60,300 € per year for transportation. The total investment costs for this solution would be around 2,895,000 € including district heating and biogas

With minimal substrate costs (see Table 8) there is no change in the optimal structure, but the revenue is higher commensurate to the lower substrate costs (one-third reduction). The revenue for the structure with minimal substrate costs excluding interest accounts for a

The biomass furnace that could be a choice to provide fermenter heating was not implemented as separate technology in PNS' maximum structure, but a price of 5 ct/kWh heat was assumed (Wagner, 2008). Produced electricity could be fed into electricity providers' grid, thus benefiting from feed-in tariffs according to Austrian's Eco-Electricity Act (RIS, n.d.).

Fig. 2. Maximum structure for PNS Optimization
